Numerical simulation of two-phase cross flow in the gas diffusion layer microstructure of proton exchange membrane fuel cells

The cross flow in the under-land gas diffusion layer (GDL) between 2 adjacent channels plays an important role on water transport in proton exchange membrane fuel cell. A 3-dimensional (3D) two-phase model that is based on volume of fluid is developed to study the liquid water-air cross flow within the GDL between 2 adjacent channels. By considering the detailed GDL microstructures, various types of air-water cross flows are investigated by 3D numerical simulation. Liquid water at 4 locations is studied, including droplets at the GDL surface and liquid at the GDL-catalyst layer interface. It is found that the water droplet at the higher-pressure channel corner is easier to be removed by cross flow compared with droplets at other locations. Large pressure difference Δp facilitates the faster water removal from the higher-pressure channel. The contact angle of the GDL fiber is the key parameter that determines the cross flow of the droplet in the higher-pressure channel. It is observed that the droplet in the higher-pressure channel is difficult to flow through the hydrophobic GDL. Numerical simulations are also performed to investigate the water emerging process from different pores of the GDL bottom. It is found that the amount of liquid water removed by cross flow mainly depends on the pore's location, and the water under the land is removed entirely into the lower-pressure channel by cross flow

Two-phase flow dynamics in the gas diffusion layer of proton exchange membrane fuel cells: Volume of fluid modeling and comparison with experiment

This paper proposes a three-dimensional (3D) volume of fluid (VOF) study to investigate two-phase flow in the gas diffusion layer (GDL) of proton exchange membrane (PEM) fuel cells and liquid water distribution. A stochastic model was adopted to reconstruct the 3D microstructures of Toray carbon papers and incorporate the experimentally-determined varying porosity. The VOF predictions were compared with the water profiles obtained by the X-ray tomographic microscopy (XTM) and the Leverett correlation. It was found local water profiles are similar in the sample’s sub-regions under the pressure difference p = 1000 Pa between the two GDL surfaces, but may vary significantly under p = 6000 Pa. The water-air interfaces inside the GDL structure were presented to show water distribution and breakthrough

Three-dimensional simulation of a new cooling strategy for proton exchange membrane fuel cell stack using a non-isothermal multiphase model

In this study, a new cooling strategy for a proton exchange membrane (PEM) fuel cell stack is investigated using a three-dimensional (3D) multiphase non-isothermal model. The new cooling strategy follows that of the Honda's Clarity design and further extends to a cooling unit every five cells in stacks. The stack consists of 5 fuel cells sharing the inlet and outlet manifolds for reactant gas flows. Each cell has 7-path serpentine flow fields with a counter-flow configuration arranged for hydrogen and air streams. The coolant flow fields are set at the two sides of the stack and are simplified as the convective heat transfer thermal boundary conditions. This study also compares two thermal boundary conditions, namely limited and infinite coolant flow rates, and their impacts on the distributions of oxygen, liquid water, current density and membrane hydration. The difference of local temperature between these two cooling conditions is as much as 6.9 K in the 5-cell stack, while it is only 1.7 K in a single cell. In addition, the increased vapor concentration at high temperature (and hence water saturation pressure) dilutes the oxygen content in the air flow, reducing local oxygen concentration. The higher temperature in the stack also causes low membrane hydration, and consequently poor cell performance and non-uniform current density distribution, as disclosed by the simulation. The work indicates the new cooling strategy can be optimized by increasing the heat transfer coefficient between the stack and coolant to mitigate local overheating and cell performance reduction

Investigating the in-/through-plane effective diffusivities of dry and partially-saturated gas diffusion layers

In this study, the effective oxygen diffusivity in the dry or partially-saturated gas diffusion layer (GDL) is numerically investigated by an oxygen diffusion model in GDLs reconstructed by a stochastic method. The predicted effective diffusivity in dry GDLs is compared with various diffusivity models from literatures. Reasonable agreements with other models were obtained. The effect of the PTFE loading in the dry Toray carbon paper is also investigated and compared with recent experimental data. It is found that the effective diffusivity becomes lower under higher PTFE loading due to the decreased pore volume, as expected. The relative effective oxygen diffusivity in partially-saturated GDLs is calculated using the two-phase volume of fluid (VOF) model and an oxygen diffusion model. The effects of different local water profiles and porosity distribution on the effective oxygen diffusivity in both the through-plane (TP) and in-plane (IP) directions are investigated and compared with a lattice Boltzmann model and experimental data. The present results are in good agreement with other studies. It is found that local water profile has significant impacts on the effective diffusivity in partially-saturated GDLs and the diffusivity in the TP direction is more sensitive to the water distribution than the IP direction

Two-phase flow and oxygen transport in the perforated gas diffusion layer of proton exchange membrane fuel cell

Liquid water transport in perforated gas diffusion layers (GDLs)is numerically investigated using a three-dimensional (3D)two-phase volume of fluid (VOF)model and a stochastic reconstruction model of GDL microstructures. Different perforation depths and diameters are investigated, in comparison with the GDL without perforation. It is found that perforation can considerably reduce the liquid water level inside a GDL. The perforation diameter (D = 100 μm)and the depth (H = 100 μm)show pronounced effect. In addition, two different perforation locations, i.e. the GDL center and the liquid water break-through point, are investigated. Results show that the latter perforation location works more efficiently. Moreover, the perforation perimeter wettability is studied, and it is found that a hydrophilic region around the perforation further reduces the water saturation. Finally, the oxygen transport in the partially-saturated GDL is studied using an oxygen diffusion model. Results indicate that perforation reduces the oxygen diffusion resistance in GDLs and improves the oxygen concentration at the GDL bottom up to 101% (D = 100 μm and H = 100 μm)